Stanley IW16 User Manual

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Page 1

IW16

HYDRAULIC

IMPACT WRENCH

SAFETY, OPERATION AND MAINTENANCE

USER'S MANUAL

Stanley Hydraulic Tools

3810 SE Naef Road

Milwaukie OR 97267-5698

503-659-5660

FAX 503-652-1780

www.stanleyhydraulic.com

Page 2

Page 3

TABLE OF CONTENTS

CERTIFICATE OF CONFORMITY......................................................................................................................................4

SAFETY SYMBOLS ............................................................................................................................................................ 5

SAFETY PRECAUTIONS ...................................................................................................................................................6

TOOL STICKERS & TAGS .................................................................................................................................................7

HYDRAULIC HOSE REQUIREMENTS ..............................................................................................................................8

HTMA REQUIREMENTS ....................................................................................................................................................9

OPERATION .....................................................................................................................................................................10

WRENCH TORQUE INFORMA TION ........................................................................................................................... 10

FACT ORS THAT AFFECT TORQUE ........................................................................................................................... 10

BOLT GRADE AND THREAD RECOMMENDATIONS ................................................................................................10

PREOPERATION PROCEDURES ..............................................................................................................................10

CHECK POWER SOURCE .........................................................................................................................................10

CONNECT HOSES ......................................................................................................................................................10

WRENCH OPERATION ...............................................................................................................................................10

COLD WEATHER OPERATION ...................................................................................................................................11

POST OPERATION UNDERWATER MODELS ONLY .................................................................................................11

EQUIPMENT PROTECTION & CARE .............................................................................................................................. 12

TROUBLESHOOTING ......................................................................................................................................................13

SPECIFICA TIONS ............................................................................................................................................................ 14

ACCESSORIES ................................................................................................................................................................14

IW16 PARTS ILLUSTRATION ..........................................................................................................................................15

IW16 EXT. HANDLE ILLUSTRATION ............................................................................................................................... 16

IW16 PARTS LIST ............................................................................................................................................................17

WARRANTY......................................................................................................................................................................18

SERVICING THE STANLEY HYDRAULIC IMPACT WRENCH: This manual contains safety, operation, and routine maintenance instructions. Servicing of hydraulic tools, other than routine maintenance, must be performed by an authorized and certiﬁ ed dealer. Please read the following warning.

SERIOUS INJURY OR DEATH COULD RESULT FROM THE IMPROPER REPAIR OR SERVICE OF THIS TOOL.

REPAIRS AND / OR SERVICE TO THIS TOOL MUST ONLY BE DONE BY AN AUTHORIZED AND CERTIFIED DEALER.

For the nearest authorized and certiﬁ ed dealer, call Stanley Hydraulic Tools at the number listed on the back of this manual and ask for a Customer Service Representative.

WARNING

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CERTIFICATE OF CONFORMITY ÜBEREINSTIMMUNGS-ZERTIFIKAT CERTIFICAT DE CONFORMITE CEE CERTIFICADO DE CONFORMIDAD CERTIFICATO DI CONFORMITA

Hydraulic Tools

______________________________________________________________________

I, the undersigned: Ich, der Unterzeichnende: Je soussigné: El abajo firmante: lo sottoscritto:

hereby certify that the construction plant or equipment specified hereunder: bestätige hiermit, daß das im folgenden genannten Werk oder Gerät: certifies par ceci que l’ usine ou l’ équipement de constructio n indiqué cidessous: por el presente certifico que la fabrica o el equipo especificado a continuacion: certifico che l’impianto o l’attrezzatura sotto specificata:

1. Category: Impact Wrench Kategorie: Catégorie: Categoria: Categoria:

2. Make/Ausführung/Marque/Marca/Marca

3. Type/Typ/Type/Tipo/Tipo: IW1615001, IW1635001, IW1615701

4. Serial number of equipment: Seriennummer des Geräts: Numéro de série de l’équipement: Numero de serie del equipo: Matricola dell´attrezzatura:

5. Year of manufacture/Baujahr/année de fabrication/Año de fabricacion/Anno di fabbricazione beginning 2005

Has been manufactured in conformity with - EEC Type examina tion as shown. Wurde hergestellt in Übereinstimmung mit - EEC Typ-Prüfung nach. Est fabriqué conformément - au(x) type(s) examiné(s) comme indiqué dans le tableau ci-après. Ha sido fabricado de acuerdo con - tipo examen EEC como dice. E’ stata costruita in conformitá con - le norme CEE come illustrato.

Burrows, James

Surname and First names/Familiennname und Vornamen/Nom et prénom/Nombre y apellido/Cognome e nome

Stanley

All

Examen CEE de type

Directive Richtlinie Directives particulières Directriz Direttiva

EN EN ISO ISO EN Machinery Directive

6. Special Provisions: None Spezielle Bestimmungen: Dispositions particulières: Provisiones especiales: Disposizioni speciali:

7. Representative in the Union: Stanley Dubuis 17-19, rue Jules Berthonneau-BP 3406 41034 Blois Cedex, France. Done at/Ort/Fait à/Dado en/Fatto a Stanley Hydraulic Tools, Milwaukie, Oregon USA Signature/Unterschrift/Signature/Firma/Firma____________________________________________________________________________ Position/Position/Fonction/Puesto/Posizione Engineering Manager

No. Nr Numéro No n.

792-6 3744 8662-7 98/37/EC

Date Datum Date Fecha Data

1994 1995 1997 1998

5/17/05

Approved body Prüfung durch Organisme agréé Aprobado Collaudato

Self Self Self Self

Date/Datum/le/Fecha/Data 5/17/05

Date of expiry Ablaufdatum Date d´expiration Fecha de caducidad Data di scadenza

NA NA NA NA

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SAFETY SYMBOLS

Safety symbols and signal words, as shown below, are used to emphasize all operator, maintenance and repair actions which, if not strictly followed, could result in a life-threatening situation, bodily injury or damage to equipment.

This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

This safety alert and signal word indicate an imminently hazardous situa-

DANGER

WARNING

CAUTION

tion which, if not avoided, will result in death or serious injury.

This safety alert and signal word indicate a potentially hazardous situation which, if not avoided, could result in death or serious injury.

This safety alert and signal word indicate a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

This signal word indicates a potentially hazardous situation which, if not avoided, may result in property damage.

This signal word indicates a situation which, if not avoided, will result in

NOTICE

IMPORTANT

Always observe safety symbols. They are included for your safety and for the protection of the tool.

damage to the equipment.

This signal word indicates a situation which, if not avoided, may result in damage to the equipment.

LOCAL SAFETY REGULATIONS

Enter any local safety regulations here. Keep these instructions in an area accessible to the operator and maintenance personnel.

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SAFETY PRECAUTIONS

Tool operators and maintenance personnel must always comply with the safety precautions given in this manual and on the stickers and tags attached to the tool and hose.

These safety precautions are given for your safety. Review them carefully before operating the tool and before performing general maintenance or repairs.

Supervising personnel should develop additional precautions relating to the speciﬁ c work area and local safety regulations. If so, place the added precautions in the space provided on page 5.

The model IW16 Hydraulic Impact Wrench will provide safe and dependable service if operated in accordance with the instructions given in this manual. Read and understand this manual and any stickers and tags attached to the tool and hose before operation. Failure to do so could result in personal injury or equipment damage.

• The operator must start in a work area without bystanders. Flying debris can cause serious injury.

• Do not operate the tool unless thoroughly trained or under the supervision of an instructor. Establish a training program for all operators to ensure safe operation.

• Always wear safety equipment such as goggles, ear and head protection, and safety shoes at all times when operating the tool. Use gloves and aprons when necessary.

• Inspect tool daily for loose fasteners, missing parts and leakage. Have tool repaired if necessary.

• The operator must be familiar with all prohibited work areas such as excessive slopes and dangerous terrain conditions.

• Maintain proper footing and balance at all times.

• Do not inspect or clean the tool while the hydraulic power source is connected. Accidental engagement of the tool can cause serious injury.

• Always connect hoses to the tool hose couplers before energizing the hydraulic power source. Be sure all hose connections are tight and are in good condition.

• Do not operate the tool at oil temperatures above 140°F/60°C. Operation at higher temperatures can cause higher than normal temperatures at the tool which can result in operator discomfort.

• Do not operate a damaged, improperly adjusted, or incompletely assembled impact wrench.

• Never wear loose clothing that can get entangled in the working parts of the tool.

• Keep all parts of your body away from the rotating parts. Long hair or loose clothing can become drawn into rotating components.

• Always use accessories that conform to the speciﬁ cations given in the OPERATION section of this manual.

• Do not reverse impact wrench rotation direction by changing ﬂ uid ﬂ ow direction.

• Release the trigger if the power supply has been interrupted.

• When working near electrical conductors, always assume that all conductors are energized and that insulation, clothing and hoses can conduct electricity. Use hose labeled and certiﬁ ed as non-conductive.

• To avoid personal injury or equipment damage, all tool repair, maintenance and service must only be performed by authorized and properly trained personnel.

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TOOL STICKERS & TAGS

Failure to use hydraulic hose labeled and certified

as non-conductive when using hydraulic tools on

or near electric lines may result in death or

For proper and safe operation read owners manual

and mwke sure that you have been properly

trained in correct procedures required for work

serious injury.

on or around electric lines.

ELECTROCUTION

HAZARD

DANGER

Failure to use hydraulic hose labeled and certified

as non-conductive when using hydraulic tools on

or near electric lines may result in death or serious injury.

For proper and safe operation read owners manual

and mwke sure that you have been properly

trained in correct procedures required for work

on or around electric lines.

12412 DANGER DECAL

28322 CE DECAL (CE)

30 LPM @ 138 B AR EHTMA CATEGORY

11207 CIRCUIT TYPE D DECAL (CE)

30136 ROTATION DIRECTION DECAL

25610 RAILROAD HELP DESK DECAL

28788

MANUAL DECAL (CE) 52539 SOUND POWER LEVEL DECAL (CE)

09612 GPM DECAL

Model No.

IW16

08153 IW16 NAME TAG (US & CE)

Stanley Hydraulic Tools

3810 SE Naef Road

Milwaukie, Oregon USA

26-45 LPM / 7-12 GPM

140 BAR / 2000 PSI

NOTE

THE INFORMATION LISTED ON THE STICKERS SHOWN, MUST BE LEGIBLE A T ALL TIMES.

REPLACE DECALS IF THEY BECOME WORN OR DAMAGED. REPLACEMENTS ARE A V AILABLE FROM YOUR LOCAL STANLEY DISTRIBUTOR.

The safety tag (p/n

15875) at right is attached to the tool when shipped from the factory. Read and understand the safety instructions listed on this tag before removal. We suggest you retain this tag and attach it to the tool

when not in use.

DANGER

1. FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED AS NON-CONDUCTIVE WHEN USING HYDRAULIC TOOLS

ON OR NEAR ELECTRICAL LINES MAY RESULT IN DEATH OR SERIOUS INJURY.

BEFORE USING HOSE LABELED AND CERTIFIED AS NON-

CONDUCTIVE ON OR NEAR ELECTRIC LINES BE SURE THE HOSE IS MAINTAINED AS NON-CONDUCTIVE. THE HOSE SHOULD BE REGULARLY TESTED FOR ELECTRIC CURRENT LEAKAGE IN ACCORDANCE WITH YOUR SAFETY DEPARTMENT INSTRUCTIONS.

2. A HYDRAULIC LEAK OR BURST MAY CAUSE OIL INJECTION INTO THE BODY OR CAUSE OTHER SEVERE PERSONAL INJURY.

A DO NOT EXCEED SPECIFIED FLOW AND PRESSURE FOR

THIS TOOL. EXCESS FLOW OR PRESSURE MAY CAUSE A LEAK OR BURST.

B DO NOT EXCEED RATED WORKING PRESSURE OF HY-

DRAU LIC HOSE USED WITH THIS TOOL. EXCESS PRESSURE MAY CAUSE A LEAK OR BURST.

C CHECK TOOL HOSE COUPLERS AND CONNECTORS DAILY

FOR LEAKS. DO NOT FEEL FOR LEAKS WITH YOUR

IMPORTANT

READ OPERATION MANUAL AND

SAFETY INSTRUCTIONS FOR THIS

TOOL BEFORE USING IT.

USE ONLY PARTS AND REPAIR

PROCEDURES APPROVED BY

STANLEY AND DESCRIBED IN THE OPERA-

SAFETY TAG P/N 15875

TION MANUAL.

TAG TO BE REMOVED ONLY BY

TOOL OPERATOR.

SEE OTHER SIDE

(shown smaller then actual size)

DANGER

D DO NOT LIFT OR CARRY TOOL BY THE HOSES. DO

NOT ABUSE HOSE. DO NOT USE KINKED, TORN OR DAMAGED HOSE.

3. MAKE SURE HYDRAULIC HOSES ARE PROPERLY CONNECTED TO THE TOOL BEFORE PRESSURING SYSTEM. SYSTEM PRESSURE HOSE MUST ALWAYS BE CONNECTED TO TOOL “IN” PORT. SYSTEM RETURN HOSE MUST ALWAYS BE CONNECTED TO TOOL “OUT” PORT. REVERSING CONNECTIONS MAY CAUSE REVERSE TOOL OPERATION WHICH CAN RESULT IN SEVERE PERSONAL INJURY.

4. DO NOT CONNECT OPEN-CENTER TOOLS TO CLOSED-CENTER HYDRAULIC SYSTEMS. THIS MAY RESULT IN LOSS OF OTHER HYDRAULIC FUNCTIONS POWERED BY THE SAME SYSTEM AND/OR SEVERE PERSONAL INJURY.

5. BYSTANDERS MAY BE INJURED IN YOUR WORK AREA. KEEP BYSTANDERS CLEAR OF YOUR WORK AREA.

6. WEAR HEARING, EYE, FOOT, HAND AND HEAD PROTECTION.

7. TO AVOID PERSONAL INJURY OR EQUIPMENT DAMAGE, ALL TOOL REPAIR MAINTENANCE AND SERVICE MUST ONLY BE PERFORMED BY AUTHORIZED AND PROPERLY TRAINED PERSONNEL.

IMPORTANT

READ OPERATION MANUAL AND

SAFETY INSTRUCTIONS FOR THIS

TOOL BEFORE USING IT.

USE ONLY PARTS AND REPAIR

PROCEDURES APPROVED BY

STANLEY AND DESCRIBED IN THE OPERA-

TION MANUAL.

TAG TO BE REMOVED ONLY BY

TOOL OPERATOR.

SEE OTHER SIDE

Page 8

HYDRAULIC HOSE REQUIREMENTS

HOSE TYPES

Hydraulic hose types authorized for use with Stanley Hydraulic Tools are as follows:  Certiﬁ ed non-conductive  Wire-braided (conductive)  Fabric-braided (not certiﬁ ed or labeled non-conductive) Hose  listed above is the only hose authorized for use near electrical conductors. Hoses  and  listed above are conductive and must never be used near electrical conductors.

HOSE SAFETY TAGS

To help ensure your safety, the following DANGER tags are attached to all hose purchased from Stanley Hydraulic Tools. DO NOT REMOVE THESE TAGS.

If the information on a tag is illegible because of wear or damage, replace the tag immediately. A new tag may be obtained from your Stanley Distributor.

THE TAG SHOWN BELOW IS ATTACHED TO “CERTIFIED NON-CONDUCTIVE” HOSE

D A N G E R

1 FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED AS NON-CONDUCTIVE

WHEN USING HYDRAULIC TOOLS ON OR NEAR ELECTRIC LINES MAYRESULT IN DEATH OR SERIOUS INJURY.

FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY

TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND ELECTRIC LINES.

2. BEFORE USING HYDRAULIC HOSE LABELED AND CERTIFIED AS NON-CONDUCTIVE ON OR NEAR ELECTRIC LINES. WIPE THE ENTIRE LENGTH OF THE HOSE AND FITTING WITH A CLEAN DRY ABSORBENT CLOTH TO REMOVE DIRT AND MOSISTURE AND TEST HOSE FOR MAXIMUM ALLOWABLE CURRENT LEAKAGE IN ACCORDANCE WITH SAFETY DEPARTMENT INSTRUCTIONS.

DO NOT REMOVE THIS TAG

SIDE 1 SIDE 2

(shown smaller than actual size)

3. DO NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE. IMPROPER USE OR HANDLING OF HOSE COULD RESULT IN BURST OR OTHER HOSE FAILURE. KEEP HOSE AS FAR AWAY AS POSSIBLE FROM BODY AND DO NOT PERMIT DIRECT CONTACT DURING USE. CONTACT AT THE BURST CAN CAUSE BODILY INJECTION AND SEVERE PERSONAL INJURY.

4. HANDLE AND ROUTE HOSE CAREFULLY TO AVOID KINKING, ABRASION, CUTTING, OR CONTACT WITH HIGH TEMPERATURE SURFACES. DO NOT USE IF KINKED. DO NOT USE HOSE TO PULL OR LIFT TOOLS, POWER UNITS, ETC.

5. CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS, BULGES, OR DAMAGE TO COUPLINGS IF ANY OF THESE CONDITIONS EXIST, REPLACE THE HOSE IMMEDIATELY. NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE.

6. AFTER EACH USE STORE IN A CLEAN DRY AREA.

D A N G E R

THE TAG SHOWN BELOW IS ATTACHED TO “CONDUCTIVE” HOSE.

D A N G E R

1 DO NOT USE THIS HYDRAULIC HOSE ON OR NEAR ELECTRIC LINES. THIS HOSE IS

NOT LABELED OR CERTIFIED AS NON-CONDUCTIVE. USING THIS HOSE ON OR NEAR ELECTRICAL LINES MAY RESULT IN DEATH OR SERIOUS INJURY.

2. FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND ELECTRIC LINES.

4. HANDLE AND ROUTE HOSE CAREFULLY TO AVOID KINKING, CUTTING, OR CONTACT WITH HIGH TEMPERATURE SURFACES. DO NOT USE IF KINKED. DO NOT USE HOSE TO PULL OR LIFT TOOLS, POWER UNITS, ETC.

DO NOT REMOVE THIS TAG

SIDE 1 SIDE 2

(shown smaller than actual size)

6. AFTER EACH USE STORE IN A CLEAN DRY AREA.

D A N G E R

SEE OTHER SIDE

DO NOT REMOVE THIS TAG

The rated working pressure of the hydraulic hose must be equal to or higher than the relief valve setting on the hydraulic system.

HOSE PRESSURE RATING

Page 9

HTMA REQUIREMENTS

TOOL CATEGORY

HYDRAULIC SYSTEM REQUIREMENTS TYPE 1 TYPEII TYPEIII TYPE RR

FLOW RATE TOOL OPERATING PRESSURE

(at the power supply outlet) SYSTEM RELIEF VALVE SETTING

(at the power supply outlet) MAXIMUM BACK PRESSURE

(at tool end of the return hose) Measured at a max. ﬂ uid viscosity of:

(at min. operating temperature) TEMPERATURE

Sufﬁ cient heat rejection capacity to limit max. ﬂ uid temperature to: (at max. expected ambient temperature)

Min. cooling capacity at a temperature difference of between ambient and ﬂ uid temps

NOTE:

Do not operate the tool at oil temperatures above 140° F (60° C). Operation at higher temperatures can cause operator discomfort at the tool.

4-6 gpm 7-9 gpm 11-13 gpm 9-10.5 gpm (15-23 lpm) (26-34 lpm) (42-49 lpm) (34-40 lpm) 2000 psi 2000 psi 2000 psi 2000 psi (138 bar) (138 bar) (138 bar) (138 bar)

2100-2250 psi 2100-2250 psi 2100-2250 psi 2200-2300 psi (145-155 bar) (145-155 bar) (145-155 bar) (152-159 bar)

250 psi 250 psi 250 psi 250 psi (17 bar) (17 bar) (17 bar) (17 bar)

400 ssu* 400 ssu* 400 ssu* 400 ssu* (82 centistokes) (82 centistokes) (82 centistokes) (82 centistokes)

140° F 140° F 140° F 140° F (60° C) (60° C) (60° C) (60° C)

3 hp 5 hp 7 hp 6 hp (2.24 kW) (3.73 kW) (4.47 kW) (5.22 kW) 40° F 40° F 40° F 40° F (22° C) (22° C) (22° C) (22° C)

FILTER Min. full-ﬂ ow ﬁ ltration Sized for ﬂ ow of at least: (For cold temp. startup and max. dirt-holding capacity)

HYDRAULIC FLUID Petroleum based (premium grade, anti-wear, non-conductive) VISCOSITY (at min. and max. operating temps)

NOTE: When choosing hydraulic ﬂ uid, the expected oil temperature extremes that will be experienced in service determine the most suitable temperature viscosity characteristics. Hydraulic ﬂ uids with a viscosity index over 140 will meet the require- ments over a wide range of operating temperatures.

*SSU = Saybolt Seconds Universal

NOTE:

These are general hydraulic system requirements. See tool Speciﬁ cation page for tool speciﬁ c requirements.

25 microns 25 microns 25 microns 25 microns 30 gpm 30 gpm 30 gpm 30 gpm (114 lpm) (114 lpm) (114 lpm) (114 lpm)

100-400 ssu* 100-400 ssu* 100-400 ssu* 100-400 ssu* (20-82 centistokes)

Page 10

OPERATION

WRENCH TORQUE INFORMATION

FACTORS THAT AFFECT TORQUE

An impact wrench is a rotary hammer that impacts the head of a bolt or nut. It does not apply a slow steady torque as a standard torque wrench. Therefore, several factors affect the result of torque when using impact wrenches:

1. LONG BOLTS. Long bolts having high-friction threads with lubrication under the bolt head or associated nut can twist when impacted, then untwist before the next impact. This will especially happen if there is low friction between the bolt head or nut and the mating surface.

2. HEAVY, LOOSE OR MULTIPLE ADAPTERS. Heavy, loose or multiple adapters between the wrench and socket can dissipate the intensity of the impact to the bolt head or nut.

3. AMOUNT OF IMPACT. Maximum torque results can be obtained by allowing continuous impacting of the socket against the bolt head or nut for at least 10 seconds.

4. HYDRAULIC FLOW RATE. If the ﬂ ow rate to the tool is too low, the hammer (or impact) speed is reduced. If the ﬂ ow is correct, a change in the relief pressure does not affect the impact force. Poorly designed hydraulic circuits can result in lower ﬂ ow rates and reduced impact speeds when pressure is required during impacting.

2. Make certain that the hydraulic power source is equipped with a relief valve set to open at 2100 psi/145 bar minimum.

3. Check that the hydraulic circuit matches the tool for open-center (oc) operation.

4. UNDERWATER MODELS ONLY. Make certain that the wrench impact mechanism is cleaned and greased with waterproof grease after each day’s use.

CONNECT HOSES

1. Wipe all hose couplers with a clean, lint-free cloth before making connections.

2. Connect hoses from the hydraulic power source to the tool ﬁ ttings or quick disconnects. It is good practice to con- nect the return hose ﬁ rst and disconnect it last to minimize or eliminate trapped pressure within the wrench.

3. Observe the ﬂ ow indicators stamped on the main body assembly and the hose couplers to ensure that the ﬂ ow is in the proper directions. The female couple on the tools “IN” port is the inlet (pressure) coupler.

Note: If the uncoupled hoses are left in the sun, pressure increase within the hoses can make them difﬁ cult to connect. Whenever possible, connect the free ends of hoses together.

WRENCH OPERATION

BOLT GRADE AND THREAD RECOMMENDATIONS

Allowable bolt torque is limited by both bolt thread diameter and grade of steel in the bolt. The IW16 Impact Wrench is recommended for use on the following bolt grade and thread sizes:

SAE Grade 2 1-1/8 to 1-7/8 inch / 28.5/47.6 mm SAE Grade 5 1 to 1-5/8 inch / 25.4-41.2 mm SAE Grade 8 7/8 to 1-3/8 inch / 22.2-35 mm

PREOPERATION PROCEDURES

CHECK POWER SOURCE

1. Using a calibrated ﬂ ow meter and pressure gauge, check that the hydraulic power source develops a ﬂ ow of 7-12 gpm/20-45 lpm at 1000-2000 psi/70-140 bar.

The IW16 is designed for 1-inch square hex drive. The 1-inch drive conﬁ guration is used with drive sockets for high impact (500-2500 ft lb / 680-3400 Nm) installation and removal of fasteners.

During normal operation it is common to see some grease leakage from around the anvil during hard use. Refer to the IW16 Service Manual for the correct lubrication procedures.

Use at the low end of the 500-2500 ft lb / 680-3400 Nm torque range during continuous use over long periods of time (impact times exceeding 10 seconds). The high temperature generated in the impact mechanism can reduce steel part and lubricant durability within the wrench.

1. Observe all Safety Precautions.

2. Move the hydraulic circuit control valve to the “ON” position to operate the wrench.

Page 11

OPERATION

WARNING

Always use sockets and accessories designed for impact type applications. DO NOT USE STANDARD SOCKETS OR ACCESSORIES. THESE CAN CRACK OR FRACTURE DURING OPERATION.

3. Select the direction of impact desired using the reversing valve located on the side of the wrench. To select clockwise direction, place the valve in the upward position. To select counter-clockwise direction, place the valve in the downward position.

Note: To more accurately tighten bolts, lubricate threads, check with a torque wrench and duplicate time of impacting for other bolts of the same length and thread size.

4. Squeeze the trigger to activate the wrench.

5. Release the trigger to stop the wrench.

EXTENSION HANDLE

If the handle and anchor block are removed, all valve handle/motor housing bolts must be cleaned, installed with loctite 242 and re-torqued. Contact Stanley authorized service for procedure.

COLD WEATHER OPERATION

If the wrench is to be used during cold weather, preheat the hydraulic ﬂ uid at low engine speed. When using the nor- mally recommended ﬂ uids, ﬂ uid temperature should be at or above 50 o F/10o C (400 ssu/82 centistokes) before use.

Damage to the hydraulic system or wrench can result from use with ﬂ uid that is too viscous or too thick.

POST OPERATION

UNDERWATER MODELS ONLY

The wrench impact mechanism must be cleaned and greased with waterproof grease after every day of use. The main housing valve and motor are sealed and do not require maintenance unless they are malfunctioning.

Remove, clean, grease and assemble the impact mechanism as described in the IW16 Service Manual.

Page 12

EQUIPMENT PROTECTION & CARE

NOTICE

In addition to the Safety Precautions in this manual, observe the following for equipment protection and care.

• Make sure all couplers are wiped clean before connection.

• The hydraulic circuit control valve must be in the “OFF” position when coupling or uncoupling hydraulic tools. Failure to do so may result in damage to the quick couplers and cause overheating of the hydraulic system.

• Always store the tool in a clean dry space, safe from damage or pilferage.

• Make sure the circuit PRESSURE hose (with male quick disconnect) is connected to the “IN” port. The circuit RETURN hose (with female quick disconnect) is connected to the opposite port. Do not reverse circuit ﬂ ow. This can cause damage to internal seals.

• Always replace hoses, couplings and other parts with replacement parts recommended by Stanley Hydraulic Tools. Supply hoses must have a minimum working pressure rating of 2500 psi/172 bar.

• Do not exceed the rated ﬂ ow (see Speciﬁ cations) in this manual for correct ﬂ ow rate and model number. Rapid failure of the internal seals may result.

• Always keep critical tool markings, such as warning stickers and tags legible.

• Tool repair should be performed by experienced personnel only.

• Make certain that the recommended relief valves are installed in the pressure side of the system.

• Do not use the tool for applications for which it was not intended.

Page 13

TROUBLESHOOTING

If symptoms of poor performance develop, the following chart can be used as a guide to correct the problem. When diagnosing faults in operation of the wrench, always check that the hydraulic power source is supplying the correct hydraulic ﬂ ow and pressure to the tool as listed in the following table. Use a ﬂ ow meter known to be accurate. Check the ﬂ ow with the hydraulic ﬂ uid temperature at least 80o F/27o C.

PROBLEM CAUSE SOLUTION

Low performance or impact. Incorrect hydraulic ﬂ ow. Check that the hydraulic power source

is producing 7-12 gpm/20-45 lpm at

1500-2000 psi/105-140 bar. Defective quick disconnects. Check each quick disconnect. Worn impact mechanism. Repair or replace the impact mecha-

nism. See Service Mechanism Re-

moval Cleaning and Installation proce-

dure to extend mechanism life. Hammer pins broken. Replace with integral frame (with

pins). Check relief adjustment screw

setting. Job may require a larger

wrench. Incorrect grease or periodic mainte-

nance of the impact mechanism is not being performed.

Spools incorrectly installed. Valve(s) incorrectly reassembled. See

Sockets or adapters too heavy or loose.

Long bolt with lubricated head. Lubricate threads only.

Wrench runs too fast. Impact mechanism or screws broken.

Grease leaks at anvil busing, wrench warm.

Grease leaks at anvil bushing, wrench cold.

Oil leak at motor cap face. Fasteners loose. Tighten to recommended torque.

Oil leaks at reversing spool. Damaged O-rings. Replace as required. Check Service

Incorrect hydraulic ﬂ ow (too high). Check that hydraulic power source

Supply and return hoses reversed. Install hoses correctly. Refer to Opera-

Relief sleeve or spring damaged. Remove and replace spool assembly. Adjusting screw is in too far. Adjust correctly. Hard duty cycle and heat forces

grease out. Main shaft O-ring leaking. Replace as required.

Face O-ring worn or missing. Replace as required. Motor cap/main housing damaged. Replace as required.

Wrong hydraulic ﬂ uid. Circuit too hot. Refer to Operation Instructions for

See Service Instructions.

Service Instructions.

Use the correct impact type sockets or

adapters.

is producing 7-12 gpm/20-45 lpm at

1500-2000 psi/105-140 bar.

tion Instructions in this manual.

Normal unless greasing instructions in

Service Instructions are not followed.

Instructions to avoid cutting O-rings on

cross holes in the spool bore.

correct ﬂ uid/circuit speciﬁ cations.

Page 14

SPECIFICATIONS

Drive Size ................................................................................................................................................1-inch Square Drive

Weight .................................................................................................................................................................26 lbs/12 kg

Overall Length ............................................................................................................................................14-1/2-inch/37 cm

Width ..................................................................................................................................................................4-inch/11 cm

Pressure Range...........................................................................................................................1500-2000 psi/105-140 bar

Flow Range ............................................................................................................................................7-12 gpm/20-45 lpm

Optimum Flow ...................................................................................................................................................8 gpm/30 lpm

System Type ....................................................................................................Open and Closed Center, HTMA Type II or III

Porting ..............................................................................................................................................................8 SAE O-Ring

Output Speed (free spin) .............................................................................................................. 2000 rpm at 5 gpm/19 lpm

Input Speed .....................................................................................................................................1200 Impacts per Minute

Connect Size and Type ...............................................................................................................3/8-inch Male Pipe Adapter

Torque........................................................................................................................................500-2500 ft. lb/680-3400 Nm

Sound Power Level ................................................................................................................................................113.2 dBA

Vibration Level

IW16 ....................................................................................................................................................................49.7 m/s

IW16157 (with Upright Extended Handle) ........................................................................................................... 18.1 m/s

Sound Pressure Level @1m ..................................................................................................................................100.2 dBA

2 2

ACCESSORIES

DESCRIPTION PART NUMBER

Adapter, 1-inch to 3/4-inch Drive ..................................................................................................................................31201

Extension, 10 inch, 1-inch Drive ..................................................................................................................................31203

Socket Retainer Pin, 1-inch Square Drive Socket ........................................................................................................33276

Socket Retainer Ring, 1-inch Square Drive Socket ......................................................................................................33277

SOCKETS

1-inch Square Drive 8-Point Deep x 1-5/16 inch ..........................................................................................................25203

1-inch Square Drive 8-Point Deep x 1-3/8 inch ............................................................................................................25204

1-inch Square Drive 8-Point Deep x 1-1/2 inch ............................................................................................................25205

1-inch Square Drive 8-Point Deep x 1-9/16 inch ..........................................................................................................25206

1-inch Square Drive 8-Point Deep x 1-3/4 inch ............................................................................................................25207

1-inch Square Drive 8-Point Deep x 1-7/8 inch ............................................................................................................25208

1-inch Square Drive 8-Point Deep x 2 inch ..................................................................................................................25209

1-inch Square Drive 8-Point Deep x 2-1/8 inch ............................................................................................................25210

1-inch Square Drive 8-Point Deep x 2-3/16 inch ..........................................................................................................25211

1-inch Square Drive 8-Point Deep x 2-1/4 inch ............................................................................................................25212

1-inch Square Drive 8-Point Deep x 2-3/8 inch ............................................................................................................25213

1-inch Square Drive 8-Point Deep x 1-5/8 inch ............................................................................................................25216

1-inch Square Drive 8-Point Deep x 1-13/16 inch ........................................................................................................25217

1-inch Square Drive 8-Point Deep x 1-11/16 inch ........................................................................................................25218

1-inch Squre Drive #70 Torx .........................................................................................................................................26456

1-inch Square Drive 8-Point Deep x 1-1/4 inch ............................................................................................................26529

1-inch Square Drive 4-Point Deep x 1 inch ..................................................................................................................27710

SOCKET SETS

Socket Set, Includes 6 Sockets ....................................................................................................................................33230

Page 15

IW16 PARTS ILLUSTRATION

Make sure the correct capscrew

is used in the correct location

Page 16

IW16 EXT. HANDLE ILLUSTRATION

EXTENED HANDLE FOR RAILROAD APPLICATIONS

SEE MAIN PARTS LIST FOR

PART NUMBERS

IF THE ANCHOR BLOCK (ITEM # 74) IS

REMOVED FROM THE VALVE HANDLE FOR

ANY REASON, THE 3 CAPSCREWS (ITEM # 76

BELOW) MUST BE CLEANED, INSTALLED WITH

242 LOCTITE AND RE-TORQUED TO 55 ft lb.

IF ALL EIGHT CAPSCREWS (ITEMS 24 & 66

FROM MAIN PARTS ILLUSTRATION PAGE)

ARE REMOVED FROM THE VALVE HANDLE,

ALL MUST BE CLEANED, INSTALLED WITH 242

LOCTITE AND RE-TORQUED TO 55 ft lb.

TORQUE TO 90 ft lb

Page 17

IW16 PARTS LIST

ITEM

PART

NO.

1 22064 1 ROD WIPER 2 00026 1 O-RING 3 22063 1 SPOOL CAP 4 06533 1 O-RING 5 23678 1 HEADED PUSH PIN 6 07998 1 ON/OFF SPOOL WELDMENT 7 07986 1 RELIEF SEAT 8 08135 1 RELIEF POPPET

9 08131 1 SPRING 10 08122 1 COIL SPRING 11 07982 1 SPRING REST 12 00255 1 O-RING

13 08137 1 14 08146 2 BUSHING

15 08123 1 IDLER SHAFT 16 00255 1 O-RING 17 08136 1 MAIN SHAFT 18 08128 1 IDLER GEAR ASSY 19 17279 1 VALVE HANDLE ASSY (INCL. ITEM 14) 20 01211 2 O-RING 21 08015 2 SPIRAL BACK-UP RING 22 08016 1 RETAINING RING 23 00706 8 LOCKWASHER 24 09284 6 CAPSCREW 1/2-13 X 1-3/4 LONG 25 58631 2 90° SWIVEL FITTING 26 56725 2 HOSE ASSY

03288 1 CAP, 3/8 IN (IW16157 ONLY)

02324 1 CAP, 1/2 IN (IW16157 ONLY) 27 05965 1 ROLL PIN 28 08133 1 TRIGGER 29 08139 1 REVERSING SPOOL 30 01607 1 SETSCREW 31 04939 1 LEVER 32 04888 1 O-RING 33 08180 1 BACK-UP RING-124 34 08125 1 SEAL BACK-UP WASHER 35 00663 1 RETAINER RING 36 00016 1 O-RING 37 00717 1 O-RING 38 07995 1 INSERT 39 08147 2 THRUST BEARING RACE 40 08148 1 THRUST NEEDLE BEARING 41 00717 1 O-RING 42 07984 1 RELIEF ADJUSTMENT SCREW 43 00429 1 HEX NUT 44 23817 1 THRUST SPACER

QTY DESCRIPTION

NO.

MOTOR HOUSING ASSY (INCL. ITEMS 14, 15, 38, 41)

ITEM

PART

NO.

45 32087 1 ASSIST HANDLE 46 09612 1 GPM STICKER 4-12 2000 47 08153 1 NAME TAG-IW16 48 24682 1 HAMMER CASE, LAND (INCL. ITEM 49) 49 21010 1 BUSHING 50 24678 1 ANVIL 51 24680 2 HAMMER PIN (INCL. ITEM 52) 52 24679 1 HAMMER FRAME 53 24677 2 HAMMER 54 --- - NO ITEM 55 --- - NO ITEM 56 00231 4 LOCK WASHER 57 09625 4 CAPSCREW 58 66305 1 STICKER, SOUND POWER (IW1615701 ONLY) 59 12412 1 STICKER, DANGER 60 28788 1 STICKER, MANUAL (IW1615701 ONLY) 61 28323 1 STICKER, CE (IW1615701 ONLY)

62 11207 1 63 24069 1 COUPLER SET

64 --- -- NO ITEM 65 30136 1 STICKER, ROTATION 66 21986 2 CAPSCREW 1/2-13 X 2-1/4 LONG 71 31916 1 REMOTE HANDLE ASSY 74 17263 1 ANCHOR BLOCK ASSY 75 00697 3 LOCKWASHER 76 21986 3 CAPSCREW 1/2-13 X 2-1/4 LONG

77 25610 1 78 371071 2 LOCKWASHER

79 10792 2 CAPSCREW 5/8-11 X 1-1/4 LONG

23134 1 STANDARD MECHANISM (INCL. ITEMS 48-53) 09602 1 SEAL KIT

QTY DESCRIPTION

NO.

STICKER, CIRCUIT TYPE D (IW1615701 ONLY)

STICKER, RAILROAD HELP DESK (IW16157 ONLY)

31916, Remote Handle Assy (see page 16).

Page 18

WARRANTY

Stanley Hydraulic Tools (hereinafter called “Stanley”), subject to the exceptions contained below, warrants new hydraulic tools for a period of one year from the date of sale to the ﬁ rst retail purchaser, or for a period of 2 years from the shipping date from Stanley, whichever period expires ﬁ rst, to be free of defects in material and/or workmanship at the time of delivery, and will, at its option, repair or replace any tool or part of a tool, or new part, which is found upon examination by a Stanley authorized service outlet or by Stanley’s factory in Milwaukie, Oregon to be DEFECTIVE IN MATERIAL AND/OR WORKMANSHIP.

EXCEPTIONS FROM WARRANTY

NEW PARTS: New parts which are obtained individually are warranted, subject to the exceptions herein, to be free of defects in material and/or workmanship at the time

of delivery and for a period of 6 months after the date of ﬁ rst usage. Seals and diaphragms are warranted to be free of defects in material and/or workmanship at the time of delivery and for a period of 6 months after the date of ﬁ rst usage or 2 years after the date of delivery, whichever period expires ﬁ rst. Warranty for new parts is limited to replacement of defective parts only. Labor is not covered.

FREIGHT COSTS: Freight costs to return parts to Stanley, if requested by Stanley for the purpose of evaluating a warranty claim for warranty credit, are covered under this policy if the claimed part or parts are approved for warranty credit. Freight costs for any part or parts which are not approved for warranty credit will be the responsibility of the individual.

SEALS & DIAPHRAGMS: Seals and diaphragms installed in new tools are warranted to be free of defects in material and/or workmanship for a period of 6 months after the date of ﬁ rst usage, or for a period of 2 years from the shipping date from Stanley, whichever period expires ﬁ rst.

CUTTING ACCESSORIES: Cutting accessories such as breaker tool bits are warranted to be free of defects in material and or workmanship at the time of delivery only. ITEMS PRODUCED BY OTHER MANUFACTURERS: Components which are not manufactured by Stanley and are warranted by their respective manufacturers.

a. Costs incurred to remove a Stanley manufactured component in order to service an item manufactured by other manufacturers. ALTERATIONS & MODIFICATIONS: Alterations or modiﬁ cations to any tool or part. All obligations under this warranty shall be terminated if the new tool or part is altered or

modiﬁ ed in any way. NORMAL WEAR: any failure or performance deﬁ ciency attributable to normal wear and tear such as tool bushings, retaining pins, wear plates, bumpers, retaining rings and

plugs, rubber bushings, recoil springs, etc. INCIDENTAL/CONSEQUENTIAL DAMAGES: To the fullest extent permitted by applicable law, in no event will STANLEY be liable for any incidental, consequential or special

damages and/or expenses.

FREIGHT DAMAGE: Damage caused by improper storage or freight handling. LOSS TIME: Loss of operating time to the user while the tool(s) is out of service. IMPROPER OPERATION: Any failure or performance deﬁ ciency attributable to a failure to follow the guidelines and/or procedures as outlined in the tool’s operation and

maintenance manual. MAINTENANCE: Any failure or performance deﬁ ciency attributable to not maintaining the tool(s) in good operating condition as outlined in the Operation and Maintenance

Manual. HYDRAULIC PRESSURE & FLOW, HEAT, TYPE OF FLUID: Any failure or performance deﬁ ciency attributable to excess hydraulic pressure, excess hydraulic back-pres-

sure, excess hydraulic ﬂ ow, excessive heat, or incorrect hydraulic ﬂ uid. REPAIRS OR ALTERATIONS: Any failure or performance deﬁ ciency attributable to repairs by anyone which in Stanley’s sole judgement caused or contributed to the failure

or deﬁ ciency. MIS-APPLICATION: Any failure or performance deﬁ ciency attributable to mis-application. “Mis-application” is deﬁ ned as usage of products for which they were not originally

intended or usage of products in such a matter which exposes them to abuse or accident, without ﬁ rst obtaining the written consent of Stanley. PERMISSION TO APPLY ANY PRODUCT FOR WHICH IT WAS NOT ORIGINALLY INTENDED CAN ONLY BE OBTAINED FROM STANLEY ENGINEERING.

WARRANTY REGISTRATION: STANLEY ASSUMES NO LIABILITY FOR WARRANTY CLAIMS SUBMITTED FOR WHICH NO TOOL REGISTRATION IS ON RECORD. In the event a warranty claim is submitted and no tool registration is on record, no warranty credit will be issued without ﬁ rst receiving documentation which proves the sale of the tool or the tools’ ﬁ rst date of usage. The term “DOCUMENTATION” as used in this paragraph is deﬁ ned as a bill of sale, or letter of intent from the ﬁ rst retail customer. A WARRANTY REGISTRATION FORM THAT IS NOT ALSO ON RECORD WITH STANLEY WILL NOT BE ACCEPTED AS “DOCUMENTATION”.

NO ADDITIONAL WARRANTIES OR REPRESENTATIONS

This limited warranty and the obligation of Stanley thereunder is in lieu of all other warranties, expressed or implied including merchantability or ﬁ tness for a particular purpose except for that provided herein. There is no other warranty. This warranty gives

vary depending upon applicable law.

the purchaser speciﬁ c legal rights and other rights may be available which might

Page 19

Stanley Hydraulic Tools

3810 SE Naef Road

Milwaukie, Oregon

503-659-5660 / Fax 503-652-1780

www.stanleyhydraulic.com